95809 Tune-Up Kit - Dynabrade Inc.

dynabrade.com

95809 Tune-Up Kit - Dynabrade Inc.

For use with:3,200 RPM Angle Head ToolsParts Page Reorder No. PD96•29Effective May, 199695809 Tune-Up KitParts included in kit are identified. See reverse side for Tune-up Instructions.02649 Bearing 54514 Blades (5) (5/pkg.)01017 Pin54523 O-Ring54515 Spacer 11016 Bearing54508 O-Ring54529 Shim Packet (as req.)54520 Bearing01041 Grease Fitting01022 Spring01024 O-Ring01025 O-Ring54520 BearingFor Models succeeding serial number N2430901041 Grease Fitting54536 Shim54542 Ball Bearing95398 Bearing54537 Ball Bearing54542 Ball Bearing54545 Shim01041 Grease FittingFor Models prior to serial number N2430954536 Shim54534 Ball Bearing95398 Ball Bearing54537 Ball Bearing54531 Needle Bearing54529 Shim*For use with models prior to S/N N24309 Only*54567 Spindle Puller *54568 Spindle WrenchDYNABRADE ®DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1490 • Phone: (716) 631-0100 • Fax: 716-631-2073 • International Fax: 716-631-2524DYNABRADE EUROPE S.àr.l., Zone Artisanale • L-5485 Wormeldange—Haut, Luxembourg • Telephone: 352 76 84 94 • Fax: 352 76 84 95© DYNABRADE, INC., 1996 PRINTED IN USA


Tune-Up InstructionsImportant: Manufactures warranty is void if tool is disassembled before warranty expires.Refer to the appropriate parts page for additional part identification.Motor Disassembly:1. Secure tool in a soft jaw vise holding onto wrench flats on rear of motor housing.2. Secure lock ring with a wrench and twist angle housing from motor housing (Note: Left hand threads).3. Remove 54526 Adapter from motor housing and loosen 01040 Lock Screw.4. Pull planetary gear assembly from motor housing. Pull motor from housing (if motor does not pull out freely, lightly tap end of housing with a rubber mallet).5. Clamp a bearing separator between the 54522 Ring Gear of the planetary carrier assembly and front 54520 Bearing (nearest to spindle end of assembly).Press bearing from carrier.6. Remove ring gear and gears. Press rear 54520 Bearing from planetary carrier.7. Press rotor from 02649 Bearing and front bearing plate. Remove 54515 Spacer, cylinder and 54514 Blades from rotor. Press 11016 Bearing from rear bearing plate.8. Remove 54505 Plug from motor housing. Remove valve assembly.9. Remove 95713 Inlet Adapter. Pry retaining ring from rear of housing and remove 54524 Muffler and 54523 O-Ring.Motor disassembly complete.Motor Reassembly:Important: Be sure parts are clean and in good repair before reassembly. Follow all torque, grease and lubrication instructions.1. Insert a .002" shim from 54529 Shim pack into front bearing plate.2. Insert new 02649 Bearing into front bearing plate.3. Place new 54515 Spacer onto pinion end of rotor. Make sure countersink faces rotor.4. Press from bearing plate assembly onto rotor until tight against spacer.5. Check clearance between rotor and bearing plate. Apply an outward (pulling) pressure on rotor. If rotor rubs bearing plate, reduce the spacing by removing shim or substitutewith .001" shim.6. Insert new 54514 Blades (lubricate blades with Dynabrade Air Lube P/N 95842 or equivalent before installation).7. Place cylinder over rotor. Be sure pin holes and air inlet holes align with holes in bearing plate.8. Press new 11016 Bearing into rear bearing plate and press assembly onto rotor. Be sure pin holes and air holes line up with holes in cylinder.9. Insert motor assembly into housing. The pin in front bearing plate should enter guide slot in housing wall.10. Install 54517 Spacer with unrelieved face towards front bearing plate.11. Press new 54520 Bearing onto front end of planetary carrier.12. Replace gears, gear shafts and ring gear (notches face rear of carrier).13. Press new 54520 Bearing onto carrier (there should be a slight drag between ring gear and bearings).14. Install planetary assembly onto motor housing. Line-up notches in ring gear with hole in housing for lock screw.15. Install lock screw until snug, then back off 1/2 turn.16. Install 54526 Adapter onto motor housing.17. Install new O-rings and spring stem assembly and replace into motor housing.18. Install new 54523 O-Ring onto muffler and replace into housing. Replace snap ring and inlet adapter.Motor reassembly complete.Angle Head Assemblies:For models succeeding S/N N24309.1. Remove retaining nut from angle housing with 5/8" hex key.2. Slide spindle assembly from housing and disassemble.3. Remove bearing cap with pin wrench and remove work spindle assembly.4. Install new 54542 Bearing and 54537 Bearing onto work spindle and insert into housing.5. Install bearing cap and test for end play. Spindle should turn freely. If there is excessive end play, insert new 54536 Shim behind 54542 Bearing.6. Reassemble spindle assembly using new 54542 Bearing, 95398 Bearing and 54545 Shim Pack (as required). Replace and tighten retaining nut.7. Test for backlash between gears. There should be .002" to .003" Backlash. Adjust using 54545 Shim Pack.For models prior to S/N N24309.Note: 54567 Spindle Puller and 54568 Spindle Wrench (or equivalent) required. These tools are not included with tune-up kit.1. Remove retaining nut from angle housing with 5/8" hex key.2. Insert 54568 Spindle wrench into spline adapter of spindle and unscrew.3. Screw female threaded end of 54567 Spindle Puller onto gear spindle. Tighten puller ring until gear spindle and 54531 Needle Bearing are removed from angle housing.4. Remove bearing cap with pin wrench and remove work spindle assembly.5. Install new 54534 Bearing and 54537 Bearing onto work spindle and insert into housing.6. Install bearing cap and test for end play. Spindle should turn freely. If there is excessive end play, insert new 54536 Shim behind 54534 Bearing.7. Insert gear spindle into housing, make sure teeth line up.8. Install new 54531 Needle Bearing into housing and onto gear spindle. Using bored end of 54568 Spindle Wrench, press 54531 Needle Bearing over gear spindle down to gear.9. Line up hole in housing with hole in gear spindle and lock together using a 3 mm pin.10. Install 95398 Bearing onto spline adapter and using 54568 Spline Wrench, tighten spline adapter onto gear spindle.11. Replace and tighten retaining nut.12. Test for backlash between gears. There should be .002" to .003" backlash. Adjust using 54529 Shim Pack.Reattach angle housing to motor housing and secure with lock ring.Motor should operate at 3,200 RPM at 90 PSI (6.2 Bar). RPM should be checked with a tachometer. If machine is running at a higher RPM then the tool should be serviced tocorrect the cause before use. Before operating, Dynabrade recommends that 2-3 drops of pneumatic tool oil be placed directly into air inlet with throttle lever depressed and thatthe gears be be greased through the grease fitting located on the motor and angle housings.

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